Deep deposition head

Abstract

Method and apparatus for depositing material in hard to reach locations of a workpiece. An elongated member is inserted in an opening. The member transports a laser beam from a fiber laser and material, preferably in powder form, to the desired location. The material is deposited on the workpiece and the laser beam contacts the material. The method and apparatus may be used to manufacture a part or to repair an existing part.

1. An apparatus for depositing material on a workpiece, the apparatus comprising:
 an elongated member comprising a deposition head at one end; 
 a fiber laser for producing a single laser beam, wherein a path of said single laser beam is internal to said elongated member; 
 at least one material delivery tube attached to or within said elongated member and terminating in a feed nozzle proximate to or within said deposition head; said feed nozzle diverging away from an elongate axis of said elongated member; 
 a mirror proximate to or within said deposition head for reflecting said single laser beam from said fiber laser out of said deposition head so that said single laser beam diverges from said elongate axis of said elongated member; 
 wherein a reflection angle of said single laser beam relative to said elongate axis of said elongated member is greater than 90 degrees; and 
 wherein material exiting said feed nozzle is contacted by said single laser beam approximately at a desired location on the workpiece. 
 
     
     
       2. The apparatus of  claim 1  wherein said elongated member comprises an aspect ratio of greater than approximately 3:1. 
     
     
       3. The apparatus of  claim 1  further comprising one or more jointed extension members. 
     
     
       4. The apparatus of  claim 3  wherein each joint comprises a mirror for reflecting or focusing said single laser beam. 
     
     
       5. The apparatus of  claim 1  wherein said deposition head is rotatable or translatable with respect to the workpiece. 
     
     
       6. The apparatus of  claim 1  wherein said deposition head is manually movable. 
     
     
       7. The apparatus of  claim 1  wherein said deposition head and elongated member fit inside an opening in the workpiece of approximately 6 inches. 
     
     
       8. The apparatus of  claim 7  wherein said deposition head and elongated member fit inside an opening in the workpiece of approximately 2 inches. 
     
     
       9. The apparatus of  claim 8  wherein said deposition head and elongated member fit inside an opening in the workpiece of approximately 0.5 inches. 
     
     
       10. The apparatus of  claim 1  wherein said workpiece is conductive. 
     
     
       11. The apparatus of  claim 10  further comprising a conductive element which is grounded when it contacts said workpiece. 
     
     
       12. The apparatus of  claim 1  wherein said material comprises a powder. 
     
     
       13. A method for depositing material on a workpiece, the method comprising the steps of:
 providing an elongated member comprising a deposition head on one end; 
 inserting the deposition head into a high aspect ratio cavity of the workpiece; 
 transporting a material to the deposition head via at least one material delivery tube attached to or within the elongated member and terminating in a feed nozzle proximate to or within the deposition head; the feed nozzle diverging away from an elongate axis of the elongated member; 
 ejecting the material from the feed nozzle and depositing the material at approximately a desired location of the workpiece; 
 transmitting a single laser beam from a fiber laser, the fiber laser disposed internally to the elongated member; 
 reflecting the single laser beam from a mirror proximate to or within the deposition head out of the deposition head at an angle relative to the elongate axis of the elongated member of greater than 90 degrees, so that the single laser beam diverges from the elongate axis of the elongated member; and 
 contacting the ejected material with the single laser beam at approximately the desired location. 
 
     
     
       14. The method of  claim 13  further comprising the step of moving the deposition head with respect to the workpiece. 
     
     
       15. The method of  claim 14  wherein the moving step is performed manually. 
     
     
       16. The method of  claim 14  wherein the moving step is performed in accordance with a computer aided design file. 
     
     
       17. The method of  claim 13  further comprising the step of cooling the deposition head. 
     
     
       18. The method of  claim 13  further comprising the step of focusing the single laser beam to a size of less than approximately 5 mm at the workpiece. 
     
     
       19. The method of  claim 18  further comprising the step of focusing the single laser beam to a size of less than approximately 1 mm at the workpiece. 
     
     
       20. The method of  claim 19  further comprising the step of focusing the single laser beam to a size of approximately 0.1 mm at the workpiece. 
     
     
       21. The method of  claim 13  wherein a minimum feature size of the deposited material is approximately 200 microns. 
     
     
       22. The method of  claim 13  further comprising the step of providing a conductive element. 
     
     
       23. The method of  claim 22  comprising the step of contacting the conductive element to the workpiece. 
     
     
       24. The method of  claim 23  further comprising the step of determining a standoff distance between the deposition head and the workpiece. 
     
     
       25. The method of  claim 13  comprising repairing or manufacturing the workpiece.